Granulated feed phosphate composition including feed enzymes

ABSTRACT

A granulated phosphate composition that provides sufficient nutritional value as well as enhanced bioavailability of organic phosphorous present in a main feed ingredient. The granulated phosphate composition includes a phosphate source, such as monocalcium phosphate, mono-dicalcium phosphate, or dicalcium phosphate, and one or more feed enzymes such as phytase. When the phosphate composition is compounded and pelleted with a main feed ingredient into a feed pellet, and consumed by a non-ruminant, the phytase component of the phosphate composition liberates otherwise unavailable phosphorous present in the main feed ingredient.

RELATED APPLICATION

The present application claims the benefit of U.S. ProvisionalApplication No. 61/776,275 filed Mar. 11, 2013, which is incorporatedherein in its entirety by reference.

FIELD OF THE INVENTION

The present invention generally relates to additives for animal feed,and more particularly a phosphate composition incorporating feed enzymesto increase the bioavailability of phosphorous by providing, in additionto the inorganic phosphorous of the phosphate composition, organicphosphorous.

BACKGROUND OF THE INVENTION

Animal and poultry feed, generally known as compound feed, arefeedstuffs that are blended from various raw materials and additives.Compound feeds can be prepared as complete feeds that provide all thedaily required nutrients, as concentrates that provide a part of theration (protein, energy), or as supplements that provide additionalmicro-nutrients such as minerals and vitamins. A main ingredient used incommercially prepared feed is feed grains such as, for example, corn,soybeans, sorghum, oats, barley, and combinations thereof.

An important industry within the animal feed industry further includesthe sale and manufacture of premixes. Premixes can be composed ofmicro-ingredients for blending into commercial or individually-producedrations to produce animal feed. Micro-ingredients can include nutrients,vitamins, minerals, chemical preservatives, antibiotics, fermentationproducts, enzymes, and other essential ingredients.

A source of phosphorous and calcium is commonly added to animal feed asa micro-ingredient. One example of such ingredient that can be used inanimal feed is Biofos®. Biofos® is a feed-grade monodicalcium phosphatethat is produced by reacting calcium carbonate and wet processdefluorinated phosphoric acid. Biofos® is a source of highly availablephosphorous (P) and calcium (Ca) with a narrow calcium-to-phosphateratio, such that it helps meet animal and poultry requirements for theseessential nutrients. For example, Biofos® guarantees a minimum 21%phosphorous content, and calcium content in a range from about 15.0 to18.0%, which allows for flexibility and economy in formulations. Biofos®also provides ease of handling and uniform dispersion in mixed feeds andminerals.

Similarly, Dynafos® is a feed grade dicalcium phosphate produced byreacting wet process defluorinated phosphoric acid with calciumcarbonate. Like Biofos®, it is a source of highly available phosphorous(P) and calcium (Ca) that has approximately a 1.1 to 1calcium:phosphorous ratio, and guarantees a minimum 18.5% phosphorouscontent, and calcium content in a range from about 20.0% to 24.0%.

Another example micro-ingredient used as a source for phosphorous andcalcium in animal feed is Multifos®. Multifos® is a feed-gradetricalcium/defluorinated phosphate, which is derived from phosphate rockin a carefully controlled thermochemical process that enhancesbiological availability, drives off fluorine, and physically conditionsthe product for feed mixing. Like Biofos®, Multifos® is a source ofhighly available phosphorous (P) and calcium (Ca), as well as sodium(Na), that will help provide animal and poultry requirements for thesenutrients. For example, Multifos® guarantees a minimum 18% phosphorouscontent, calcium content in a range from about 30.0 to 34.0%, and sodiumcontent around 5%, which again allows flexibility in feed formulation.

Yet another example micro-ingredient used as a source for phosphorousand calcium in animal feed is Nexfos®. Nexfos® is a granulatedfeed-grade monodicalcium phosphate incorporating lubricity andabrasivity additives for high throughput and improved energyefficiencies in pelletizing processes. Like Biofos®, Nexfos® is a sourceof highly available phosphorous (P), calcium (Ca), and sodium (Na), witha narrow calcium-to-phosphate ratio, such that it helps meet animal andpoultry requirements for these essential nutrients. For example, Nexfos®guarantees minimum 19% phosphorous content, calcium content in a rangeof from about 15.0% to 18.0%, and sodium content in a range of fromabout 4.0% to 5.0%, which allows for flexibility and economy informulations. Such composition is described in one or both of U.S. Pat.No. 8,012,519 entitled “Granulated monocalcium phosphate productcontaining abrasivity and lubricity additives,” and U.S. PatentApplication Publication No. 2011/0293792 entitled “Granulated phosphateproduct containing abrasivity and lubricity additives,” both of whichare incorporated herein by reference in their entireties.

Feed blends are formulated according to specific requirements of atarget animal. Feed manufactures or compounders prepare the blends bybuying the commodities, i.e. the main ingredients, such as, for example,corn, soybeans, sorghum, oats, and barley, and any desiredmicro-ingredients, and blending or compounding them in a feed millaccording to specifications provided by a nutritionist, for example. Theblends can be manufactured by feed compounders as meal type, pellets, orcrumbles.

One type of feed mill found in the industry for producing feed blends isa pellet mill, which blends a mixture of dry powdered feedstock, suchas, for example, flour or grass, a wet ingredient, such as steam ormolasses, and any other ingredients, such as micro-ingredients. The dryfeedstock, wet ingredient, and any other ingredients are combined toform a mash or meal. The mash or meal is then compacted into an interiorof a round die that contains many small holes. The mash or meal iscompacted within the die thereby forcing it out of the holes in the formof pellets, to ultimately be fed to livestock.

Although the micro-ingredients provide a highly bioavailable source ofinorganic phosphorous, organic phosphorous is also present in animalfeed in plant tissue that makes up the main ingredient. However, thisphosphorous is present as phytic acid, or inositol hexakisphophate(phytate in salt form), which is indigestible to nonruminant animals,such that the organic phosphate is not available to the animal, and isexcreted to the surrounding environment. This unabsorbed or unavailablephosphorous can become potentially hazardous to the immediatesurroundings, if introduced into the environment in large quantities.

It is known in the art to add a feed enzyme to animal feed as a separatemicro-ingredient, as discussed, for example, in a publication entitled“Considerations on the use of microbial phytase,” by Cefic (January,2006). A suitable feed enzyme, phytase, or myo-inositol hexakisphosphatephosphohydrolase, is any type of phosphatase enzyme that catalyzes thehydrolysis of phytic acid, rending the phosphorous digestible, such thatthe organic phosphorous becomes an added source of phosphorous. Phytaseis typically bulk blended with the inorganic source of phosphorous, suchas Biofos®, Multifos®, Dynafos® or Nexfos®. However, differences inparticle size causes settling during transportations and/or storage suchthat stratification occurs, resulting in uneven distribution of phytasein each animal pellet, and therefore variability in phosphorous content.

Alternatively, separate transportation and storage of the feed enzyme isrequired, and the feed enzyme is added to the feed composition duringpelleting. However, this requires additional storage space, additionalmanufacturing steps, and potential added cost for having an additionalcomponent to be added.

There remains a need for a phosphate ingredient or feed additive foranimal feed directly incorporating a feed enzyme, such that theconsistent amounts of feed enzyme and inorganic phosphorous isdistributed throughout each feed pellet after pelleting, therebyrendering both inorganic and organic phosphorous highly available in theanimal feed.

SUMMARY OF THE INVENTION

Embodiments of the present disclosure are directed to a granulatedphosphate composition feed additive for incorporation into animal andpoultry feed that provides sufficient nutritional value includingphosphorous availability, by rendering both organic and inorganicsources of phosphorous in the feed highly bioavailable. Optionally, theanimal feed can have enhanced pelleting benefits, such as abrasivenessand lubricity. More particularly, the compositions of the embodiments ofthe present invention provide similar or better nutritional value thanother feed-grade micro-ingredients, such as a Multifos® or Biofos®product, by facilitating the liberation of otherwise unavailable organicphosphorous in the feed base composition. Further, the compositions ofthe embodiments are manufactured using a granulation process as opposedto a more expensive rotary kiln process.

In particular, the compositions of the embodiments provide a source ofinorganic phosphorous in the form of monocalcium phosphate (Ca(H₂PO₄)₂or calcium dihydrogen phosphate), dicalcium phosphate (CaHPO₄ dibasiccalcium phosphate), and/or mono-dicalcium (a chemically obtainedintermediate between monocalcium phosphate and dicalcium phosphate orCaHPO4, Ca(H2PO4)₂·H2O), as well as an enzyme to liberate organicphytate-bound phosphorous that is present in the vegetable-based orgrain feed materials.

In some aspects, the compositions of embodiments of the presentinvention can include a granulated phosphate feed ingredient compositioncomprising a phosphate source such as monocalcium phosphate,mono-dicalcium phosphate, dicalcium phosphate, or combinations thereof,and a feed enzyme present in an amount of about that will provideapproximately 200 to 2,000 FYU (phytase units) per kilogram (FTU/kg) ofcompounded or complete feeds. The feed enzyme can comprise, for example,a phytase including a histidine acid phosphatase (HAP), a β-propellerphytase, a purple acid phophatase (PAP), a protein tyrosine phosphatase(PTP), or combinations thereof. More specifically, the phytase cancomprise a highly specific phytase for phytic acid, such as phytasesfrom Bacillus sp., Aspergillus sp., E. coli and those phytases belongingto the class of PTP-like phytases.

In some aspects, the compositions of embodiments of the presentinvention further comprise one or more additional feed enzymes, such as,for example, amylases, xylanases, and proteases. Other feed enzymes aidin the digestion or breakdown of certain components in the base feedcomposition, making additional sources of nutrition bioavailable to theanimal and/or aiding in the digestion of the animal feed. These otherenzymes can be present in an amount of about 50 to 500 grams per ton ofcomplete feeds.

Amylase is an enzyme which catalyzes the breakdown of starch into sugarsfor its absorption. More particularly, starch is a complex carbohydrateor polysaccharide, and therefore a large molecule. Because the cells inthe body include a partially permeable membrane, they cannot absorbthese starches unless they are broken down into glucose.

Xylanase is an enzyme for breaking down non-starch polysaccharides(NSPs). For example, xylanases degrade the linear polysaccharidebeta-1,4-xylan into xylose, thus breaking down hemicellulose, one of themajor components of plant cell walls. This is important because ashemicellulose increases, voluntary feed intake, or the amount of feedeaten by animal when the feed is given to it without restriction,decreases because the undigested polysaccharides increase thegastrointestinal viscosity in the digestive tract due to their bindingto water and selling. Therefore, by breaking down hemicellulose orreducing its presence, voluntary feed intake will not be negativelyaffected. Furthermore, xylanases aid in the release of nutrientsotherwise trapped in the cell walls of plants used in the animal feed.

Proteases are enzymes that break down proteins in food so that they aredigestable and absorbable. Similarly to starches, because the cells inthe body include a partially permeable membrane, they cannot absorbcomplex, long chain proteins unless they are broken down to liberate theamino acids needed by the body. Specifically, proteases are enzymes thatconduct proteolysis, that is, begin protein catabolism by hydrolysis ofthe peptide bonds that link amino acids together in the polypeptidechain forming the protein, so that the body's cells can absorb the aminoacids.

In some aspects, the compositions of embodiments of the presentinvention can further include a lubricity additive in the form of asodium additive to generate sodium phosphate to lubricate the die duringpelleting to prevent or inhibit product buildup and clogging of the die.The sodium additive is present in an amount that provides a sodiumcontent of about one to about ten percent by weight of the composition.The sodium additive can comprise, for example, sodium carbonate, sodiumhydroxide, monosodium phosphate, potash, or combinations thereof.

In yet other aspects, the compositions of embodiments of the presentinvention can optionally include an abrasive or abrasivity additive thataids in scouring and cleaning the die during pelleting operations. Theabrasivity additive is present in an amount of about one to about tenpercent by weight of the composition. The abrasive additive cancomprise, for example, silica, such as silica sand.

In yet other aspects, embodiments of the present invention can comprisean animal feed base material, and a granulated phosphate compositionincluding a source of inorganic phosphorous and a feed enzyme, whereinthe animal feed is pelleted via a pellet mill. The phosphate sourcecomprises as monocalcium phosphate, mono-dicalcium phosphate, dicalciumphosphate, or combinations thereof, and the feed enzyme comprises aphytase.

The above summary of the invention is not intended to describe eachillustrated embodiment or every implementation of the present invention.The detailed description that follows more particularly exemplifiesthese embodiments.

DETAILED DESCRIPTION

In one embodiment of the present invention, a granulated phosphate feedadditive composition for incorporation into an animal feed formulationincludes a phosphate source, such as monocalcium phosphate,mono-dicalcium phosphate, dicalcium phosphate, or combinations thereof,and one or more feed enzymes. The one or more feed enzymes can provideproduct attributes, such as, for example, the ability to liberateorganic sources of phosphorous available in the feed material such as,for example, flour, grass, a vegetable material, and/or feed grains suchas corn, soybeans, sorghum, oats, rye, and barley and the like, orcombinations thereof. The granulated phosphate product can providenutritional attributes, such as, for example, sufficient availability ofphosphorous, calcium, and/or sodium, in a final feed formulation thatare similar to or exceed those currently exhibited by the addition ofexisting feed-grade micro-ingredients, such as Multifos® and Biofos® tothe final feed formulation.

In one particular embodiment, a phosphate source is produced by areaction of calcium carbonate and wet process defluorinated phosphoricacid, forming a slurry of monocalcium phosphate, mono-dicalciumphosphate, dicalcium phosphate, or combinations thereof. Temperature,reactant levels, and other factors allows for the amounts or ratio ofdesired forms of the phosphate source slurry. The slurry is then sent toa granulator, such as a rotating drum granulator, to produce granules ofthe phosphate product.

One or more feed enzymes are introduced into the phosphate slurry beforegranulation and/or during granulation. The feed enzyme is typically inthe form of a powder, granules, or liquid form. In an embodiment of theinvention, a feed enzyme is introduced in an amount such that it ispresent in an amount of about 200 to 2,000 FTU/kg of complete feed.

The feed enzyme can comprise, for example, a phytase including ahistidine acid phosphatase (HAP), a β-propeller phytase, a purple acidphophatase (PAP), a protein tyrosine phosphatase (PTP), or combinationsthereof. More specifically, the phytase can comprise a highly specificphytase for phytic acid, such as phytases from Bacillus sp., Aspergillussp., E. coli and those phytases belonging to the class of PTP-likephytases.

The phosphate composition according to embodiments of the inventionprovides sufficient nutrients to the final feed product for consumptionby the target animal. In one embodiment of the present invention, thephosphate composition comprises a monocalcium phosphate or monodicalciumphosphate, having a minimum phosphorous content of about 21% P, and aminimum sodium content of 4% Na. Furthermore, the phosphate compositioncan closely resemble the currently available Biofos® product in that thephosphate composition comprises a calcium content in a range from about15% to about 30%, a maximum fluorine content of about 0.21%, a bulkdensity of about 56-59 lbs/ft³, a moisture content of about 1%, and a pHof about 3.6. A sieve analysis using a Tyler mesh scale, in which themesh size is the number of openings per (linear) inch of mesh, can alsoresemble the Biofos® product, wherein 99.7% of the granules pass a 12Mesh screen, 88% pass a 16 Mesh screen, 73.4% pass a 20 Mesh screen, and1.0% pass a 100 Mesh screen.

In another embodiment of the invention, the phosphate compositioncomprises a monocalcium phosphate or monodicalcium phosphate having aminimum phosphorous content of about 18% P, and a minimum sodium contentof 4% Na. Furthermore, the phosphate composition can closely resemblethe currently available Nexfos® product in that the phosphatecomposition comprises a calcium content in a range from about 15% toabout 18%, a maximum fluorine content of about 0.18%, a bulk density ofabout 82-85 lbs/ft³, a moisture content of about 0.6%, and a pH of about6.0. A sieve analysis using a Tyler mesh scale, in which the mesh sizeis the number of openings per (linear) inch of mesh, can also resemblethe Multifos® product, wherein 98.1% of the granules pass a 12 Meshscreen, 4.9% pass a 100 Mesh screen, and 1.2% pass a 200 Mesh screen.

In yet another embodiment of the invention, the phosphate compositioncomprises a dicalcium phosphate having a minimum phosphorous content ofabout 18.5% P, and a calcium content in a range from about 20.0 to 24.0%Ca. Furthermore, the phosphate composition can closely resemble thecurrently available Dynafos® product in that a maximum fluorine contentis about 0.185%, a bulk density of about 57-60 lbs/ft³, a moisturecontent of about 1%, and a pH of about 4.0. A sieve analysis using aTyler mesh scale, in which the mesh size is the number of openings per(linear) inch of mesh, can also resemble the Dynafos® product, wherein99.6% of the granules pass a 12 Mesh screen, 82.6% pass a 20 Meshscreen, 9.9% pass a 48 Mesh screen, and 0.4% pass a 100 Mesh screen.

The phosphate composition can optionally comprise one or more additionalfeed enzymes, such as, for example, amylases, xylanases, and/orproteases, added to the phosphorous slurry before and/or duringgranulation. Other feed enzymes aid in the digestion or breakdown ofcertain components in the base feed composition, making additionalsources of nutrition bioavailable to the animal and/or aiding in thedigestion of the animal feed. These other enzymes can be present in anamount of about 50 to 500 g per ton of complete feeds.

The phosphate compositions can optionally include a sodium additivepresent in an amount that provides a sodium content of about one toabout ten percent by weight of the composition. The sodium additive cancomprise, for example, sodium carbonate, sodium hydroxide, monosodiumphosphate, potash, or combinations thereof.

In yet another embodiment, the compositions of embodiments of thepresent invention can optionally include an abrasive or abrasivityadditive in an amount of about one to about ten percent by weight of thecomposition. The abrasive additive can comprise, for example, silica,such as silica sand. The optional lubricity and abrasivity additiveshelp to reduce product build-up in the pelleting die as discussed indetail in U.S. Pat. No. 8,012,519 and U.S. Patent ApplicationPublication No. 2011/0293792, both of which were previously incorporatedby reference in their entireties.

The phosphate composition feed additive according to embodiments of theinvention is blended with the appropriate main feed ingredient atamounts formulated according to specific requirements of a targetanimal. The phosphate composition is added to the main feed ingredients,such as, for example, corn, soybeans, sorghum, oats, rye, barley, andany other desired micro-ingredients. The mix is blended or compoundingin a feed mill, such as a pellet mill, according to specificationsprovided by a nutritionist, for example. The blends can be manufacturedby feed compounders as meal type, pellets, or crumbles, as discussedabove.

In one particular embodiment, the phosphate composition is blended withthe main feed ingredient and any other desired micro-ingredient in apellet mill. In the pellet mill, a mixture of dry powdered feedstock,such as, for example, flour, grass, corn, soybeans, sorghum, oats, rye,barley, or combinations thereof, a wet ingredient, such as steam ormolasses, the phosphate composition, and any other ingredients, such asmicro-ingredients are combined to form a mash or meal. The mash or mealis then compacted into an interior of a round die of the pellet millthat contains many small holes. The mash or meal is compacted within thedie thereby forcing it out of the holes in the form of pellets, toultimately be fed to livestock.

The phosphate composition, due to the addition of the feed enzyme, makeavailable an additional source of phosphorous to the animal whencompounded with the main feed ingredient that can be made up of, forexample, corn, soy, wheat, or the like, or combinations thereof. Asdiscussed in the Background section, organic phosphorous is present inthe grains and plants of the main feed ingredient as phytic acid orphytate. This phytic acid itself is indigestible to non-ruminant animalsrendering the phosphorous an unavailable source. However, phytic acidhas six phosphate groups that are available for release by phytases atdifferent rates and in different order. Phytases hydrolyze phosphatesfrom phytic acid in a stepwise manner, yielding products that againbecome substrates for further hydrolysis. Most phytases are able tocleave five of the six phosphate groups from phytic acid, therebyrendering the otherwise phytate-bound phosphorous bioavailable to theanimal. Therefore, by incorporating the phytase into the phosphatecomposition, which is then compounded and pelleted with the main feedingredient, such as via a pellet mill, the phytase can liberate thisorganic source of phosphorous in the main feed ingredient when theanimal feed pellets are consumed by the animal.

The present invention may be embodied in other specific forms withoutdeparting from the essential attributes thereof; therefore, theillustrated embodiments should be considered in all respects asillustrative and not restrictive.

What is claimed is:
 1. A granular phosphate additive to be added as acomponent in an animal feed formulation, the phosphate additivecomprising: a phosphate source co-granulated with a feed enzyme, whereinthe phosphate source has a minimum phosphorous content of at least 18%.2. The granular phosphate additive of claim 1, wherein the phosphatesource comprises monocalcium phosphate, mono-dicalcium phosphate,dicalcium phosphate, or combinations thereof.
 3. The granular phosphateadditive of claim 1, wherein the feed enzyme is selected from the groupconsisting of phytases, amylases, xylanases, proteases, and combinationsthereof.
 4. The granular phosphate additive of claim 3, wherein the feedenzyme comprises a phytase.
 5. The granular phosphate additive of claim4, wherein the phytase is present in an amount such that the phytasefrom about 200 to about 2,000 FTU per kilogram of animal feedformulation.
 6. The granular phosphate additive of claim 3, furthercomprising one or more additional feed enzymes selected from the groupconsisting of amylases, xylanases, proteases, and combinations thereof.7. The granular phosphate additive of claim 6, wherein the one or moreadditional feed enzymes are present in an amount to provide from about50 to about 500 grams per ton of animal feed formulation.
 8. Thegranular phosphate additive of claim 1, further comprising a sodiumadditive, wherein the sodium additive is present in an amount thatprovides a sodium content of about one to about ten percent by weight ofthe composition.
 9. The granular phosphate additive of claim 8, whereinthe sodium additive comprises sodium carbonate, sodium hydroxide,monosodium phosphate, or combinations thereof.
 10. The granularphosphate additive of claim 1, further comprising an abrasive orabrasivity additive that is configured to scour and clean the die duringpelleting of the animal feed formulation.
 11. The granular phosphateadditive of claim 10, wherein the abrasivity additive is present in anamount of about one to about ten percent by weight of the composition.12. The granular phosphate additive of claim 10, wherein the abrasiveadditive comprises silica.
 13. The granular phosphate additive accordingto claim 1, wherein the granulated phosphate composition comprises aphosphorous content of at least about eighteen percent by weight of thecomposition.